Surface cooler and method of forming

ABSTRACT

A surface cooler configured to be operably coupled to an aircraft fan casing and having a first surface configured to confront a peripheral wall of an aircraft fan casing and a second surface opposite the first surface, a set of fluid passages internal to the body and a set of fins located on at least a portion of the second surface of the body.

BACKGROUND

Contemporary engines used in aircraft produce substantial amounts ofheat that must be transferred away from the engine. Heat exchangersprovide a way to transfer heat away from such engines. For example, heatexchangers can be arranged in a ring about a portion of the engine. Onetype of heat exchanger used is a surface cooler that is mounted to anaft fan casing.

BRIEF DESCRIPTION

Aspects of the present disclosure relate to a surface cooler assembly,including a surface cooler configured to be operably coupled to anaircraft fan casing and having a first surface configured to confront aperipheral wall of an aircraft fan casing and a second surface oppositethe first surface, the surface cooler, including a body defining thefirst surface and the second surface, a set of fluid passages internalto the body and a set of fins located on at least a portion of thesecond surface of the body; and a first manifold portion unitarilyformed with the body and having a first interior passage fluidly coupledto at least one of the set of fluid passages and one of redirects a flowto another of the set of fluid passages or provides an inlet to the atleast one of the set of fluid passages.

Another aspect of the present disclosure relates to a method of forminga surface cooler, the method including forming a base body defining afirst exterior surface and a second exterior surface opposite the firstexterior surface and having a set of fluid passages internal to the basebody and wherein the base body is configured to be operably coupled to afan casing of an aircraft engine and forming a first manifold portionunitarily formed with the base body and having a first interior passagefluidly coupled to at least one of the set of fluid passages and whereinthe first interior passage is configured to one of redirect a flow toanother of the set of fluid passages or provide an inlet to the at leastone of the set of fluid passages.

Yet another aspect of the present disclosure relates to a method ofrepairing a surface cooler, the method including depositing metal on aportion of a surface cooler assembly, comprising a surface coolerconfigured to be operably coupled to an aircraft fan casing and having afirst surface configured to confront a peripheral wall of an aircraftfan casing and a second surface opposite the first surface, the surfacecooler including a body defining the first surface and the secondsurface, a set of fluid passages internal to the body and a set of finslocated on at least a portion of the second surface of the body and atleast a first manifold having a first interior passage fluidly coupledto at least one of the set of fluid passages and wherein the firstmanifold one of redirects a flow to another of the set of fluid passagesor provides an inlet to the at least one of the set of fluid passageswherein depositing metal includes laser metal deposition on at least oneof a scratch, gouge, or foreign object damage portion of the surfacecooler assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a schematic partially cut away view of a turbine engineassembly with a surface cooler in accordance with aspects of the presentdisclosure.

FIG. 2 is a perspective view of a portion of a surface cooler that canbe included in the turbine engine assembly of FIG. 1.

FIG. 3 is a perspective view of a base body that can be used to form thesurface cooler of FIG. 2.

FIG. 4 is an enlarged perspective view of a portion of the base body ofFIG. 3.

FIG. 5 is a schematic view illustrating laser metal deposition on aportion of the base body of FIG. 4.

FIG. 6 illustrates cross-sectional views of portions of a surface coolerthat can be included in the turbine engine assembly of FIG. 1.

DETAILED DESCRIPTION

Aspects of the present disclosure relate to surface coolers for aircraftengines. It will be understood that the space in this region of theengine is limited and current designs utilize nearly all the availablespace. As a result, newer engine technologies, which have more heat thatmust be dissipated, will be thermally constrained due to the lack ofspace available. The problem is further exacerbated in that new enginedesigns are becoming further space constrained, making the size, andweight of the current types of coolers and their mounting systemsprohibitive. An additional problem is that the heat exchangers aresubject to relatively harsh environments within the engine relativelyhigh temperatures that cause them to expand thermally, especiallylaterally or tangential, yet need to remain fixed to the engine toprevent high cycle fatigue from engine vibration. Generally, such heatexchangers are line replaceable units and require servicing while theengine is mounted to the wing of the aircraft. Thus, a mounting systemthat allows for ease of mounting while still allowing for thermal growthand providing the desired stability is necessary.

The exemplary surface coolers can be used for providing efficientcooling. Further, the term “surface coolers” as used herein can be usedinterchangeably with the term “heat exchangers.” As used herein, thesurface coolers are applicable to various types of applications such as,but not limited to, turbojets, turbo fans, turbo propulsion engines,aircraft engines, gas turbines, steam turbines, wind turbines, waterturbines, and other automotive or industrial applications. Surfacecoolers can include, but are not limited to, integrated drive generatorsurface cooler, variable frequency starter generator cooler, or a lubesurface cooler. While “a set of” various elements will be described, itwill be understood that “a set” can include any number of the respectiveelements, including only one element. As used herein, the terms “axial”or “axially” refer to a dimension along a longitudinal axis of acomponent or along a longitudinal axis of the component. All directionalreferences (e.g., radial, axial, upper, lower, upward, downward, left,right, lateral, front, back, top, bottom, above, below, vertical,horizontal, clockwise, counterclockwise) are only used foridentification purposes to aid the reader's understanding of thedisclosure, and do not create limitations, particularly as to theposition, orientation, or use thereof. Connection references (e.g.,attached, coupled, connected, and joined) are to be construed broadlyand can include intermediate members between a collection of elementsand relative movement between elements unless otherwise indicated. Assuch, connection references do not necessarily infer that two elementsare directly connected and in fixed relation to each other. Theexemplary drawings are for purposes of illustration only and thedimensions, positions, order, and relative sizes reflected in thedrawings attached hereto can vary.

Thus, referring to FIG. 1, a brief explanation of the environment inwhich embodiments of the invention can be used is described. Morespecifically, FIG. 1 illustrates an exemplary turbine engine assembly 10having a longitudinal axis 12. A turbine engine 16, a fan assembly 18,and a nacelle 20 can be included in the turbine engine assembly 10. Theturbine engine 16 can include an engine core 22 having compressor(s) 24,combustion section 26, turbine(s) 28, and exhaust 30. An inner cowl 32radially surrounds the engine core 22.

Portions of the nacelle 20 have been cut away for clarity. The nacelle20 surrounds the turbine engine 16 including the inner cowl 32. In thismanner, the nacelle 20 forms an outer cowl 34 radially surrounding theinner cowl 32. The outer cowl 34 is spaced from the inner cowl 32 toform an annular passage 36 between the inner cowl 32 and the outer cowl34. The annular passage 36 characterizes, forms, or otherwise defines anozzle and a generally forward-to-aft bypass airflow path. A fan casing37 having an annular forward casing 38 and an annular aft casing 52 canform a portion of the outer cowl 34 formed by the nacelle 20 or can besuspended from portions of the nacelle 20 via struts (not shown).

In operation, air flows through the fan assembly 18 and a first portion40 of the airflow is channeled through compressor(s) 24 wherein theairflow is further compressed and delivered to the combustion section26. Hot products of combustion (not shown) from the combustion section26 are utilized to drive turbine(s) 28 and thus produce engine thrust.The annular passage 36 is utilized to bypass a second portion 42 of theairflow discharged from fan assembly 18 around engine core 22.

The turbine engine assembly 10 can pose unique thermal managementchallenges and a surface cooler or surface cooler 50 can be attached tothe turbine engine assembly 10 to aid in the dissipation of heat. In theexemplary embodiment, the surface cooler 50 is an annular surface coolerthat can be operably coupled to an annular aft casing 52 that forms aninterior portion of the outer cowl 34.

The surface cooler 50 can be an annular surface cooler located radiallyabout the about turbine engine 16. The surface cooler 50 can include,but is not limited to, an air-cooled heat exchanger that is positionedwithin the annular passage 36. While the surface cooler 50 has beenillustrated as being downstream of the fan assembly 18 it is alsocontemplated that the surface cooler 50 can alternatively be upstreamfrom fan assembly 18. As such, it will be understood that the surfacecooler 50 can be positioned anywhere along the axial length of theannular passage 36. The annular aft casing 52 and surface cooler 50 canform a portion of a fan casing assembly.

FIG. 2 illustrates one exemplary embodiment of a portion of the surfacecooler 50 having a body 48 defining a first surface 54 and a secondsurface 56 that is opposite that of the first surface 54. Whenassembled, the first surface 54 confronts the annular aft casing 52. Thesurface cooler 50 can include a circumferential and axial profile thatis substantially similar to the circumferential and axial profile of theannular aft casing 52. It will be understood that the surface cooler 50can cover any portion of the circumference of the annular aft casing 52.It will be understood that a set of surface coolers 50 can be utilizedto cool a single turbine engine assembly 10. The first surface 54 hasbeen illustrated as including a forward edge projection 58 and an aftedge projection 60. Although it will be understood that this need not bethe case. Such forward edge projection 58 and aft edge projection 60 canbe used for mounting the surface cooler 50 to hooks or other mountingfeatures of the annular aft casing 52.

Generally, a set of cooling passages 62 extend at least a portion of alength of the body 48 from a first distal end 64 to a second distal end66. It will be understood that any number of cooling passages can belocated internally of the body 48. Two cooling passages 62 have beenillustrated in FIG. 2 for the sake of clarity.

A set of fins 68 define a portion of the second surface 56 of the body48. It will be understood that while some of the fins 68 have been shownas being more discrete and some of the fins 68 have been shown as alonger solid body that any suitable type, size, profile, and shape arecontemplated. Further still, the longer solid body is merely for claritysake, and it will be understood that only discrete fins can be included.In one non-limiting example, the fins 68 can include thin metal shavingsskived from the body 48.

An inlet/outlet manifold portion 70 is included in the body 48 at thefirst distal end 64 and includes an inlet 72 and an outlet 74. The inlet72 can be fluidly coupled to at least one of the set of cooling passages62 to provide hot liquid thereto. The outlet 74 is fluidly coupled toanother of at least one of the set of cooling passages 62 to direct hotliquid therefrom. In this manner, it will be understood that theinlet/outlet manifold portion 70 overlies or is adjacent to at least aportion of the set of cooling passages 62. A bypass valve section 71 canbe fluidly coupled such that hot liquid introduced bypasses the set ofcooling passages 62 and is not cooled. A first attachment boss 73 isalso illustrated as being included and can be utilized to operablycouple the annular aft casing 52 and surface cooler 50.

Further still, in the illustrated example, fins 68 are located on thesecond surface 56 opposite the location of the inlet/outlet manifoldportion 70. This allows for heat to be directed out of fluid that iswithin the inlet/outlet manifold portion 70. Alternatively, it will beunderstood that fins need not be located on the second surface oppositethe location of the inlet/outlet manifold portion 70.

By way of non-limiting example, fins are not located opposite of areturn manifold portion 76 of the body 48. It will be understood,however, that they can be located on the second surface 56 furthertowards or adjacent the second distal end 66. The return manifoldportion 76 is also unitarily formed with the body 48 and includes atleast one return fluid passage 78 fluidly coupled to at least two of theset of cooling passages 62 to fluidly couple them together. The returnmanifold portion 76 is configured to redirect a direction of fluid flowfrom one of the set of cooling passages 62 to the second of the set ofcooling passages 62.

A set of mounting bosses 80 can be included on the first surface 54. Theset of mounting bosses 80 can be unitarily formed with the body 48 andcan be utilized to operably couple the annular aft casing 52 and surfacecooler 50. It will be understood that the mounting boss 80 can take anynumber of suitable shapes and sizes.

Aspects of the present disclosure include the forming of the body 48including the integral unitarily formed inlet/outlet manifold portion70, the integral unitarily formed return manifold portion 76, and theintegral unitarily formed mounting bosses 80. The process of forming canstart with forming the base body as illustrated in FIG. 3. It will beunderstood that any of the suitable portions of the base body 82 asdescribed in FIG. 2 can be initially be formed as part of the base body82 including, but not limited to, the first surface 54, second surface56, first distal end 64, second distal end 66, cooling passages 62, orfins 68. The initial base body 82 can be an aluminum base body, by wayof non-limiting example, that is extruded with such features.Alternatively, the base body 82 can be formed in any other suitablemanner. Alternatively or additionally, additional material can beextruded on the second surface 56 such that the set of fins 68 can beformed from the additional material, such as via skiving.

It is contemplated that a first portion of the base body 82 can beremoved, this has been indicated generally at 84. Removal of the firstportion forms a depression 86 in the base body 82 and the first surface54. It is contemplated that the cooling passages 62 can also be removedfrom the base body 82 to form the depression 86, leaving only the fins68 and a fin-wall 69 joining the fins 68 together as more clearly shownin FIG. 4. The removal can be done in any manner including that the basebody 82 can be machined away by way of non-limiting example.

Inlet/outlet manifold portion 70 can then be unitarily formed with aremainder of the base body 82 including onto the depression 86 andoperably coupled with exposed cooling passages 62. It is contemplatedthat the inlet/outlet manifold portion 70 can be unitarily formed with aremainder of the base body 82 in any suitable manner including viaadditive manufacturing technologies such as electrodeposition or lasermetal deposition technology (LMDT).

FIG. 5 more clearly illustrates the inlet/outlet manifold portion 70being constructed via LMDT. More specifically, in LMDT a nozzle 90 isutilized to deposit material 92 onto the depression 86 of the base body82 to build the inlet/outlet manifold portion 70 onto the base body 82such that the body 48 is an integrally formed unitary monolithic body.The layers of deposit material 92 are shaped such that the inlet/outletmanifold portion 70 are built onto the base body 82 so that the inlet 72and outlet 74 (FIG. 2) of the inlet/outlet manifold portion 70 aresealingly fluidly coupled with cooling passages 62, respectively.

As shown in FIG. 5, the LMDT works by injecting metal powder 94 via thenozzle 90 into a laser beam 96 that converges on the surface of thedepression 86 and forms a melt pool 98. Shield gasses can also beutilized separately as indicated with arrows 100 or in combination withthe metal powder 94 fed through the nozzle 90. One benefit of suchadditive manufacturing techniques is that the inlet/outlet manifoldportion 70 can be unitarily formed with the base body 82. It will beunderstood that the depression 86 and the base body 82 including thefirst surface 54 are curved surfaces as the surface cooler 50 is anannular surface cooler configured to surround an engine. Such curvedsurfaces can be considered complex surfaces in which not all additivemanufacturing techniques can be applied. It is also contemplated thatLMDT can be utilized to unitarily form the boss(es) 80 (FIG. 2) with thebase body 82. The boss(es) 80 could be printed via LMDT as solidstructures and then be drilled and tapped for staked inserts (notshown).

It will be understood that once the surface cooler has been fully formedit can then be positioned such that the first surface 54 confronts theannular aft casing 52. The body 48 can then be fixed to and extendedfrom the annular aft casing 52 by the bosses 80 or any other suitablefastening mechanism. In this manner, the body 48 can be suspended fromthe annular aft casing 52.

FIG. 6 illustrates another alternative method of forming a portion of asurface cooler 150 a, 150 b. The surface cooler 150 a, 150 b is similarto the surface cooler 50; therefore, like parts will be identified withlike numerals increased by 100, with it being understood that thedescription of the like parts of the surface cooler 50 applies to thesurface cooler 150 a, 150 b, unless otherwise noted. In the illustratedexample, much like the earlier described process, the process of formingthe surface cooler as illustrated at 150 a can start with forming a basebody 182, which can include including the first surface 154, secondsurface 156, cooling passages 162, and fins 168. Again, the base body182 can be extruded with such features. Alternatively or additionally,additional material can be extruded on the second surface 56 such thatthe set of fins 168 can be formed there from such as via skiving.

A first portion of the base body 182 can be removed, this has beenindicated generally at 184, to form a depression 186 in the base body182 and the first surface 154. It is contemplated that the removedportion 184 can include that the cooling passages 162 can also beremoved from the base body 182 to form the depression 186 leaving onlythe fins 168 and fin-wall 169.

Also illustrated is that an expander body 171 having a set of fluidpassages 173 can then be unitarily formed onto the depression 186 andoperably coupled with exposed cooling passages 162. It is contemplatedthat the expander body 171 can be unitarily formed with the base body182 in any suitable manner including via additive manufacturingtechnologies such as electrodeposition or laser metal depositiontechnology (LMDT). While only a single fluid passage 173 has beenillustrated for clarity it will be understood that the expander may havea same number of fluid passages as the cooling passages 162.Alternatively, the number of fluid passages 173 can be different thanthe number of cooling passages 162. As illustrated it is contemplatedthat the expander body 171 allows for a height of the fluid passages tobe increased over a length of the unitarily formed expander body 171from a first portion 175 to a second portion 177 of the expander body171. This includes that the interior height of the fluid passages 173therein can also be increased as better shown in the cross-section at150 b.

The surface cooler 150 b also illustrates that an inlet/outlet manifold185 has been welded at weld joints 181 to the expander body 171. Theweld joints 181 run along upper and lower portions of the inlet/outletmanifold 185 and the expander body 171. Material from the weld joints181 can extend into the fluid passage 187 of the inlet/outlet manifold185 and the fluid passage 173 of the expander body 171. Such material183 is often called weld-drop-through. In operation, if the fluidpassages did not have the increase in height provided by the expanderbody 181 the weld-drop-through would hinder the flow of fluid duringoperation. Essentially, the weld-drop-through would otherwise cause aconstriction and narrow the fluid passage causing a pressure change thesurface cooler. However, the inclusion of the unitarily formed expanderbody 171 allows a manifold 185 having larger channels to be welded tothe base body 182 lessening the impact of any weld-drop-through. In thismanner the expander body 171 allows welding but avoids excessiveoil-side pressure drop by allowing for a transition in height betweenthe base body 182 to the inlet/outlet manifold 185.

Alternatively, it has been determined that instead of removing an upperportion of the base body to create a depression as previously describedand illustrated that slots or other channels can be machined, includingvia wire EDM, into the upper surface as necessary to provide access tothe cooling passages 62. LMDT could also be utilized to providestrengthening features within a portion of the surface cooler includingwithin the machined channels. Further still LMDT could be used on thesurface coolers described herein to add additional surface area featuresto maximize heat transfer.

It has also be contemplated that LMDT can be utilized for joining ofparts or portions on a surface cooler such as those described above. Forexample, LMDT could be utilized to fluidly attach manifolds such asinlet/outlet manifold or return manifold to a curved cooling passagesections of a surface cooler to replace typical welding or brazing. Inthis manner aspects of the present disclosure enable or provide forcontrolling weld-drop-through so to minimize or eliminate drop-throughin the fluid passage at the weld joint. This can be particularlybeneficial in heat exchangers where pressure changes can be damaging.Aspects of the present disclosure have been specifically describe withrespect to high pressure heat exchangers including surface coolers in anengine such as an aircraft engine. Such heat exchangers can operate atpressures from ˜20 atm to 68 atm (˜300 psi to 1000 psi). Because LMDTcreates a small melt pool at the surface of deposition weld-drop-throughinto the fluid passages themselves can be avoided. While this can bebeneficial in many types of components it has been found of particularbenefit in heat exchangers including those of high pressure such asaircraft surface coolers. Aspects of the present disclosure allowssmaller channel heights because space does not need to be left fordrop-through this in turn results in oil velocity maximization andbetter heat transfer coefficients. This also allows for the surfacecoolers to be smaller and to fit better into the tightly designed spacesand for them to have less weight. Because aspects of the presentinvention have a reduction of pressure changes they allow for componentsto be formed with thinner walls allowing for better heat transfer andadditional weight reduction, which is particularly beneficial inaircraft as it directly relates to fuel consumption and cost benefits.

LMDT could also be used for repair of surface coolers or other complexparts or heat exchangers and is not restricted to typical additiveprocesses that require flat powder beds. This can be particularlybeneficial as LMDT can be utilized to repair surface coolers returningfrom field operation with scratches, gouges, or foreign object damage.

The above-described embodiments provide for a compact and simplifieddesign that provides a variety of additional benefits including ease ofassembly and that no welding is required. Further, the simplified designprovides a variety of additional benefits including elimination ofexpensive cast manifolds, elimination of weld-drop-through, andunitarily formed attachments. Aspects of the present disclosure alsoprovide for a repair option for returned surface coolers.

To the extent not already described, the different features andstructures of the various embodiments can be used in combination witheach other as desired. That one feature is not illustrated in all of theembodiments is not meant to be construed that it cannot be, but is donefor brevity of description. Thus, the various features of the differentembodiments can be mixed and matched as desired to form new embodiments,whether or not the new embodiments are expressly described. Allcombinations or permutations of features described herein are covered bythis disclosure.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to practice the invention, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined by the claims, and can include other examplesthat occur to those skilled in the art. Such other examples are intendedto be within the scope of the claims if they have structural elementsthat do not differ from the literal language of the claims, or if theyinclude equivalent structural elements with insubstantial differencesfrom the literal languages of the claims.

What is claimed is:
 1. A surface cooler assembly, comprising: a surfacecooler configured to be operably coupled to an aircraft fan casing andhaving a first surface configured to confront a peripheral wall of anaircraft fan casing and a second surface opposite the first surface, thesurface cooler, comprising: a body defining the first surface and thesecond surface; a set of fluid passages internal to the body and a setof fins located on at least a portion of the second surface of the body;and a first manifold portion unitarily formed with the body and having afirst interior passage fluidly coupled to at least one of the set offluid passages and one of redirects a flow to another of the set offluid passages or provides an inlet to the at least one of the set offluid passages.
 2. The surface cooler assembly of claim 1 wherein thefirst manifold portion further includes a second interior passagefluidly coupled to at least one other of the set of fluid passages andprovides an outlet to the at least one other of the set of fluidpassages such that the first manifold portion defines an inlet/outletmanifold portion.
 3. The surface cooler assembly of claim 2 wherein theinlet/outlet manifold portion includes fins located on the portion ofthe second surface of the body opposite the inlet and the outlet.
 4. Thesurface cooler assembly of claim 2, further comprising a second manifoldportion unitarily formed with the body and having a third interiorpassage fluidly coupled to at least two of the set of fluid passages andconfigured to form a return passage and redirects a flow of fluid fromone of the two set of fluid passages to the other.
 5. The surface coolerassembly of claim 4 wherein the second surface underlying the secondmanifold is devoid of fins.
 6. The surface cooler assembly of claim 4wherein the surface cooler is an air cooled oil cooler.
 7. The surfacecooler assembly of claim 6 wherein the surface cooler includes at leastone of an integrated drive generator surface cooler, variable frequencystarter generator cooler, or a lube surface cooler.
 8. The surfacecooler assembly of claim 4, further comprising attachment mechanismsunitarily formed with the body.
 9. The surface cooler assembly of claim8 wherein the attachment mechanisms include a set of bosses unitarilyformed with the body and extending from the first surface.
 10. Thesurface cooler assembly of claim 1 wherein the first manifold portioncomprises an expander body and the first interior passage extends from afirst end of the expander body to a second end of the expander body,which is fluidly coupled to the at least one of the set of fluidpassages.
 11. The surface cooler assembly of claim 10 wherein the firstinterior passage includes a first height at the first end and a secondheight at the second end and wherein the first height is larger than thesecond height.
 12. The surface cooler assembly of claim 11, furthercomprising a cast manifold mounted to the first end of the expanderbody.
 13. The surface cooler assembly of claim 12 wherein the castmanifold is welded to the first end of the expander body.
 14. Thesurface cooler assembly of claim 1 wherein surface cooler is an annularsurface cooler and the first surface is a curved surface.
 15. A methodof forming a surface cooler, the method comprising: forming a base bodydefining a first exterior surface and a second exterior surface oppositethe first exterior surface and having a set of fluid passages internalto the base body and wherein the base body is configured to be operablycoupled to a fan casing of an aircraft engine; and forming a firstmanifold portion unitarily formed with the base body and having a firstinterior passage fluidly coupled to at least one of the set of fluidpassages and wherein the first interior passage is configured to one ofredirect a flow to another of the set of fluid passages or provide aninlet to the at least one of the set of fluid passages.
 16. The methodof claim 15 wherein forming the base body comprises extruding the basebody.
 17. The method of claim 16 wherein forming the first manifoldportion comprises building the first manifold portion via laser metaldeposition.
 18. The method of claim 17, further comprising forming asecond manifold portion unitarily formed with the base body and havinganother interior passage fluidly coupled to at least two of the set offluid passages and configured to form a return passage that redirects aflow from one of the two set of fluid passages to the other.
 19. Themethod of claim 15, further comprising forming a first set of finslocated on the second exterior surface of the base body.
 20. A method ofrepairing a surface cooler, the method comprising: depositing metal on aportion of a surface cooler assembly, comprising a surface coolerconfigured to be operably coupled to an aircraft fan casing and having afirst surface configured to confront a peripheral wall of an aircraftfan casing and a second surface opposite the first surface, the surfacecooler including a body defining the first surface and the secondsurface, a set of fluid passages internal to the body and a set of finslocated on at least a portion of the second surface of the body and atleast a first manifold having a first interior passage fluidly coupledto at least one of the set of fluid passages and wherein the firstmanifold one of redirects a flow to another of the set of fluid passagesor provides an inlet to the at least one of the set of fluid passages;wherein depositing metal includes laser metal deposition on at least oneof a scratch, gouge, or foreign object damage portion of the surfacecooler assembly.